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Recommendations for
Gearbox Reliability
A Dodge Maxum Reducer drives a silo vertical elevator
(bucket elevator) at a cement plant. The current PM procedure
requires oil changes each year, per the OEM guideline.
The lubricant
selection guideline suggests:
an AGMA #4 oil for ambient temperatures from 15°F
- 55°F
an AGMA #5 oil for ambient temperatures from
55°F
– 125°F
Annual ambient temperature average for your area is
78°F, with a temperature range for the last calendar
year from 15°F to 104°F.
Operating temperature for each of the units ranges between >100°F
and 135°F. The units are always changed per
the PM schedule even though the oil never appears to
be spoiled.
The local lubricant supplier has recommended a synthetic
220 EP to extend the lubricant life cycles.
Analysis is currently conducted on an semi-annual basis,
with samples collected from a mini-mess sampling port
at the side of the housing. This particular unit has
been in production for 3 years and is showing the first
signs of wear (Fe @ 45PPM on the last oil sample). This
is a critical production function and it operates 24/7.
Oil samples often show high silicon levels as well.
Recommend any improvements to support the lubrication-related
issues that could keep the unit running reliably. You have a complete selection
of tools and materials available
for
your use.
Factors to consider:
1. Effect of temperature
2. Lubricant selection
3. Seals and breathers
4. Filtration
5. Oil sample port location and sample frequency
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